Comfortable Protective Garments

ABSTRACT

Garment constructs and garments prepared therefrom having a functional layer and an inner layer of a plurality of textiles, at least two of which are dissimilar textiles, adhered to the functional layer are provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.11/867,921 filed Oct. 5, 2007 (pending), the contents of which areincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to garment constructs and garments preparedtherefrom having a functional layer and an inner layer formed of aplurality of textiles, at least two of which are dissimilar textiles,adhered to the functional layer. In some embodiments, the garmentconstructs or garments prepared therefrom have an outer layer adhered tothe side of the functional layer opposite to the inner layer.

BACKGROUND OF THE INVENTION

Garments have been described having an outer protective layer ordinarilypermeable to liquid water and a waterproof breathable layer affixedinside the outer layer. Optionally, these constructs are provided withan adjacent, but not affixed, inner liner textile.

Garments have also been constructed using a waterproof lining, generallyformed from pattern pieces cut out of sheets and then joined together atseams, typically by sewing. This lining is generally loosely disposedagainst the inner side of the outer layer. However, air gaps between theouter layer and the waterproof lining reduce water vapor permeabilityand heat transmission. Further, all sewn seams must be water-proofed byproviding seam tape over the seam on the surface of the functionalwaterproof layer.

Garments have been described wherein the outer material is adhered tothe functional waterproof layer before pattern pieces of the garment arecut out. In this embodiment, the functional layer must have as manyperforating seams as are required for the outer material includingdecorative seams and seams required for appliqués. Thus, the lining sideof these garments contains a large number of seam sealing tapes whichare unattractive, create friction upon contact with the body and canbecome detached upon rubbing against the body.

Articles of the present invention have been described containing anouter material part adhered via a continuous or discontinuous adhesivelayer to a functional layer part composed of a plurality of pieces ofwaterproof, water-vapor-permeable functional materials. The outermaterial and functional material composites are joined together bystitched seams which are each waterproofed by waterproof seam sealingtape placed on the functional layer surface oriented towards the outermaterial part.

SUMMARY OF THE INVENTION

An aspect of the present invention relates to garments or garment panelscomprising a functional layer having a first side and a second side; aninner textile layer comprising a plurality of dissimilar textile piecesforming a non-homogenous surface; and a discontinuous adhesive layerwhich affixes the inner textile layer to the first side of thefunctional layer. The dissimilar textile pieces of the inner textilelayer can be abutted to each other or have at least portions of whichare free of contact with each other.

The garment or garment panel may further comprise an outer textile layeraffixed to the second side of the functional layer. This outer textilelayer may be seamless or may comprise a plurality of dissimilar textilepieces abutted together to form a non-homogenous surface.

Another aspect of the present invention relates to garments or garmentpanels comprising a functional layer having a first side and a secondside; an inner textile layer comprising a plurality of dissimilartextile pieces forming a non-homogenous surface; and a discontinuousadhesive layer which affixes the inner textile layer to the first sideof the functional layer.

Another aspect of the present invention relates to a method of making agarment construct. In this method, a functional layer having a firstside and a second side and an outer perimeter is provided. An innertextile layer comprised of a plurality of textile pieces, at least twoof which are dissimilar is then affixed to the first side of thefunctional layer via a discontinuous layer of adhesive to form anon-homogenous surface. In some embodiments, this method furthercomprises affixing an outer textile layer with an outer perimeter to thesecond side of the functional layer.

Yet another aspect of the present invention relates to a method ofmaking a garment. In this method, a functional layer with a first sideand a second side is provided. An outer textile layer is affixed to thesecond side of the functional layer to create an outer shell or bondshell material or laminate. The outer shell material is then cut to formgarment constructs. A plurality of textile pieces, at least two of whichare dissimilar, are also provided for an inner layer of the garmentconstruct. The inner layer textile pieces are cut to form a desiredpattern. These inner layer textile pieces are then affixed in thedesired pattern to the first side of the functional layer of the outershell garment or garment panel via a discontinuous adhesive layer. Thesegarment constructs are assembled via seams to form a finished garment.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side view of the layers in an exemplary bondable shelluseful in producing garments or garment panels in accordance with thepresent invention.

FIG. 2 is a side view of the layers of an exemplary bondable shellwherein the layer of discontinuous adhesive in the form of dots is firstapplied to a release layer and subsequently transferred to the firstside of the functional layer.

FIG. 3 is a side view of the layers of an exemplary garment constructcreated with a bondable shell and two dissimilar liner textiles.

FIG. 4 is a side view of the layers of an exemplary garment portionformed with an inner textile layer and comprising a sewn-on pocket.

FIG. 5 shows a side view of the layers of an exemplary garment orgarment panel formed using an inner textile layer comprised of aplurality of dissimilar textile pieces, namely an insulation-filledtextile and a second textile.

FIG. 6A shows a top view of an exemplary garment or garment panel formedusing textile pieces having different stretch characteristics.

FIG. 6B is a side view of the layers of an exemplary garment or garmentpanel formed using an inner textile layer comprised of a plurality oftextiles having differing stretch characteristics.

FIG. 7 shows a side view of an exemplary garment or garment panel formedusing inner textile pieces having different air permeabilities.

FIG. 8A is a side view of the layers of an exemplary garment or garmentpanel having a plurality of dissimilar textile pieces forming an innertextile layer that covers at least a portion of the bondable shell.

FIG. 8B is a top view of an exemplary garment or garment panel having aplurality of dissimilar textile pieces forming an inner textile layerwhich covers at least a portion of a bondable shell.

FIG. 9 shows a side view of an exemplary seam sealed garment or garmentpanel formed by affixing a bondable shell to a liner comprising multipledissimilar textiles.

FIG. 10 shows a cross section of a drawstring tunnel.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides durably waterproof, highly breathablemultilayered garment constructs with improved design freedom for garmentproduction.

The present invention also relates to methods for producing thesegarment constructs and garments thereof.

By “bondable shell” as used herein it is meant at least one textile ornon-textile material which is able to be bonded to an inner lining orother layer. Preferably the bondable shell further comprises afunctional layer and adhesive.

By “garment construct” as used herein it is meant one or multiple joinedpanels of textile laminates which, upon assembly, make up a finishedgarment.

By “textile laminate” as used herein it is meant a textile or aplurality of textile pieces adhered to a functional layer.

By “textile” as used herein it is meant any wovens, nonwovens, felts,knits, natural fiber materials, synthetic fiber materials and isinclusive of, but not limited to leathers, vinyls, or other protectivematerials useful in garment construction.

By “dissimilar textile pieces” as used herein it is meant two or moretextile pieces exhibiting different textile characteristics including,but not limited to, material contents, thicknesses, breathabilitycharacteristics, waterproof characteristics, insulation, and othermeasurable textile characteristics. A plurality of dissimilar textilepieces is two or more.

By “non-homogenous surface” as used herein it is meant the surfacetopography resulting from the joinder of two or more dissimilar textilepieces.

By “discontinuous adhesive” as used herein it is meant the adhesive isdisposed in any manner that does not fully cover or coat a given side ofa functional layer textile, or textile layer, including, but not limitedto, discrete adhesive dots, lines of adhesive, adhesive grid patterns,random adhesive patterns, or any other arrangement that bonds the innertextile pieces to the first side of the functional layer so that thelargest distance between any two adjacent bond points is less than 2 cm.The close proximity of bond points ensures intimate contact between thebonded layers.

The present invention provides garment constructs useful in theproduction of garments.

A garment or garment panel of the present invention comprises afunctional layer. The functional layer 7 preferably comprises at leastone material which is waterproof or waterproof and breathable, thefunctional layer 7 can be a single material or a combination ofmaterials. Examples of materials which may be present in the functionallayer include, but are not limited to microporouspolytetrafluoroethylene (PTFE) membranes, dense PTFE, or PTFE membranecoated with protective coatings such as polyurethanes, or polyolefinfilms, polyurethane films, silicone and silicone-containing films,polyester films, as well as other fluoropolymer containing films such asskived PTFE and fluorinated ethylene propylene (FEP), composite barriermembranes, composites having microporous polytetrafluoroethylene (PTFE)membranes. The functional layer 7 is preferably a seamless layer or amembrane layer of fewer pieces than either the outer shell or the innerlayer of the garment construct to reduce the required seam sealingneeded.

The garment or garment panel of the present invention further comprisesan inner textile layer. The inner textile layer comprises a plurality oftextile pieces, at least two of which are dissimilar, thereby forming anon-homogenous surface. Examples of dissimilar textile pieces useful inthis layer include, but are not limited to textiles such as lightweightknits, heavyweight knits, fleeces, wovens, batting, such as Primaloft®insulation, or down-filled baffle chambers with our without quilting,other thermally insulating materials, and foams. The dissimilar textilepieces of the inner textile layer can be abutted to each other or can befree of contact with each other. The inner layer of the garment orgarment panel may cover all or a portion of the functional layer.

The ability to use dissimilar textile pieces in the inner layer of thegarment constructs of the present invention provides for more flexibleand stylish design of garments with targeted regions of breathability,stretch, warmth, softness and/or aesthetics integrated into the garmentupon its production.

The garment or garment panel further comprises a discontinuous adhesive10 layer which affixes the inner textile layer to a first side of thefunctional layer. This discontinuous adhesive 10 layer of the garment orgarment panel is preferably a re-meltable adhesive. The adhesive usedfor the present invention can be applied in either a discontinuous orcontinuous pattern. In order to maintain breathability when a continuousadhesive pattern is used, the adhesive must be breathable. If adiscontinuous adhesive 10 pattern is used, the adhesive 10 can be eitherbreathable or non-breathable. Because a discontinuous pattern of hotmeltable adhesive dots can be applied by a variety or methods, thespecific hot melt adhesive should be chosen so that its rheologicalcharacteristics match those required by the application process as wellas by the end application. For instance, in garment applications, thehot melt adhesive should have a remelt temperature higher than that ofconsumer garment heat cycles such as home laundry, home drying, drycleaning, and ironing. In addition, the hot melt adhesive should have aremelt temperature low enough to minimize damage to textiles (e.g.glazing, chemical breakdown, dye transfer or shade change.) Given theseupper and lower temperature constraints, the hot melt adhesive ideallyhas a softening point between 170 degrees Fahrenheit and 350 degreesFahrenheit. Meltable polyurethane adhesives which are suitable for thisapplication can be formulated in accordance with U.S. Pat. No. 4,814,412or are commercially available from various suppliers such as Bostick,Noveon, and other polyurethane adhesive suppliers.

In one embodiment, the garment or garment panel further comprises anouter textile layer 15 affixed to the second side of the functionallayer. Examples of outer textile layers include, but are not limited towovens, knits, non-wovens, The outer textile layer 15 may be a seamlesslayer of the garment or garment panel or may comprise a plurality ofdissimilar textile pieces abutted together to form a non-homogenoussurface. The functional layer 7 and the outer textile layer 15 of thegarment or garment panel are preferably aligned so that the outerperimeter of the functional layer 7 and the outer perimeter of the outertextile layer 15 are coincident with each other.

The garment or garment panel of the present invention is useful inproduction of simple and stylish garments which are preferablylight-weight, waterproof and breathable as well as aestheticallypleasing on the inside and outside of the garment. The ability to usedissimilar textile pieces in the inner layer allows flexibility inproduction of garments with targeted regions of breathability and/orwarmth through use of dissimilar textile regions of, for example,down-filled baffles, polyester batting insulation, fleece, light-weightknits, heavy-weight knits, wovens, and/or no textile at all.

The garment or garment panel of the present invention is additionallyuseful in production of garments having regions of specificfunctionality. For example, the inner textile layer may comprise adissimilar textile piece having a low-wicking property located in chosenregions as to provide low wicking to the garment or garment panel and/orfinished garment. Low wicking may be desirable around garment openingsincluding, but not limited to the sleeve cuffs, garment hemline, andcollar regions. In yet another permutation of this invention, innertextile pieces containing an anti-microbial agent or anti-odor agent canbe incorporated into the inner textile layer so that the resultinggarment provides odor control in specific areas including but notlimited to the underarms, and other high perspiration areas.

In another embodiment, the present invention can be useful to impartvarying stretch characteristics within a garment construct. By providingstretch textile pieces as part of inner textile layer, a garment orgarment panel can be made which has differing stretch characteristicswithin a garment construct. Thus, this invention allows designers tomake protective garments with longitudinal stretch in some regions,transverse stretch in other regions, bi-directional stretch in yet otherregions, and no stretch in yet other regions. Thus, protective garmentswith varied regional stretch are able to be created without the use ofseams 23 in the protective layer.

The present invention further allows the inner layer of a garment to beassembled into a finished lining for the garment independent of theexterior shell of the garment. The advantage to this is that the liningand the exterior shell may then be placed into relative contact witheach other and heat and pressure can be used to set the liner to theexterior shell. It is a surprising result to be able to easily form agarment with waterproof or liquid proof seams 23 and a customizablelining. Other benefits include but are not limited to performancemapping of the outside of the garment by the use of materials having lowand high abrasion characteristics without affecting the interior mappingof comfort/insulation. Also, color blocking designs can be done on theoutside of a garment without disrupting the inner textile layer design.

FIG. 1 is a side view of the layers in an exemplary bondable shell 5useful in producing garments or garment panels in accordance with of thepresent invention. In this embodiment, the bondable shell 5 comprises anouter (face) textile layer 15 affixed to the second side 9 of afunctional layer 7. In this embodiment, a layer of discontinuousadhesive 10 in the form of thermoplastic adhesive dots is applied to thefirst side 8 of the functional layer 7 for further affixing of an innertextile layer (not shown) having a plurality of textile pieces, at leasttwo or which are dissimilar, thereto.

FIG. 2 is a side view of the layers and a method of producing anexemplary bondable shell 5 wherein the layer of discontinuous adhesive10 is shown as dots and is first applied to a release layer 17 (depictedas release paper) and subsequently transferred to the first side 8 ofthe functional layer 7. The second side 9 of the functional layer 7 isoptionally affixed to an outer textile layer 15. The release layer 17 isremoved after the discontinuous adhesive 10 is affixed to the functionallayer 7.

FIG. 3 is a side view of the layers of an exemplary bondable shell 5comprising an outer textile layer 15 and a functional layer 7 and havinga discontinuous adhesive 10 useful to affix an inner textile layer 20.In this embodiment, the inner textile layer 20 is comprised of aplurality of dissimilar textile pieces (e.g., liner textile 1 and linertextile 2) affixed via the discontinuous adhesive 10 to the first side 8of the functional layer 7.

FIG. 4 is a side view of the layers of an exemplary garment portionformed with an inner textile layer 20 and comprising a sewn-on pocket22. The inner textile layer 20 is then affixed via a discontinuousadhesive 10 to the first side 8 of the functional layer 7. Thefunctional layer 7 with adhesive dots 10, and the outer textile layer 15are joined to form a bondable shell 5. This construction of a garment orgarment panel enables the pocket 22 to be sewn to the inner textilelayer 20 and then joined to the bondable shell 5 without requiring thestitch 21 to penetrate the functional or liquid-proof membrane layer 7.

FIG. 5 shows a side view of the layers of an exemplary garment orgarment panel formed using an inner textile layer 20 comprised of aplurality of dissimilar textile pieces, namely an insulation-filledtextile 18 and a second textile 19. As illustrated, theinsulation-filled textile 18 is formed having multiple insulation-filledchambers 24. The chambers 24 are formed of at least two similar ornon-similar textiles with seams 23 which may be stitched, glued orwelded to house the insulation 25. The insulation-filled liner 20 isthen affixed via a discontinuous adhesive 10 to one side of thefunctional layer 7, thereby avoiding penetration of the functional layer7 by the seams 23 used to form the chambers 24, and incorporating thechambered liner 20 onto a bondable shell 5 to create a desired garmentor garment panel.

FIG. 6A shows a top view of an exemplary garment or garment portionhaving an inner textile layer 20 formed using textiles 25 havingdifferent stretch characteristics and a non-stretch textile 30. Bycombining non-stretch textiles 30 and stretch textiles 20 for thedissimilar textile pieces used to form a textile layer, an inner textileliner 20 can be created having different amounts of stretch anddifferent stretch orientations. As shown in FIG. 6B, the inner textilelayer 20 formed in this embodiment is then affixed via discontinuousadhesive 10 to the first side 8 of the functional layer 7, therebyavoiding penetration of the functional layer 7. The functional layer 7is shown bonded to an outer textile layer 15.

FIG. 7 shows a side view of an exemplary garment or garment panel formedwith an inner textile layer 20 having textile pieces each havingdifferent air permeability rates. By combining low air permeabilitytextiles and high air permeability textiles as dissimilar textile piecesused to form a textile layer, an inner textile liner is created havingregions with differing air permeability rates affixed to awater-resistant membrane barrier or functional layer 7 and an outertextile layer 15 to form a garment or garment portion having regions ofdiffering air permeabilities.

FIG. 8A is a side view of an exemplary garment or garment panel having aplurality of dissimilar textile pieces namely, liner textile 1 and linertextile 2, forming an inner textile layer 20 which covers at least aportion of the bondable shell 5 having a functional layer 7. It may bedesirable to have more than half of the bondable shell 5 covered withthe inner textile layer 20 for certain apparel. FIG. 8B is a top view ofan exemplary garment or garment panel having dissimilar textile pieces(liner textile 1, liner textile 2, liner textile 3, and liner textile 4)and a portion 35 with no liner textile. FIG. 8A illustrates anembodiment having approximately 70% of the bondable shell 5 covered withthe inner textile layer 20.

Also provided is a process for production of a garment of the presentinvention. The bondable shell 5 as described in FIG. 1 may be providedas a roll or in a sheet form. Garment constructions are formed from thebondable shell 5 laminate. It may be desirable to provide at least twodifferent textiles on rolls for the inner textile layer. Dissimilartextile pieces are then assembled into desired inner textile layers. Theouter shell garment constructions to which the inner textile layers areaffixed may be constructed independent of the inner layer constructions.Alternatively panels may be constructed which comprise at least innertextile layers and outer textile layers, so that the panels may beassembled into a final form creating a garment or article. Optionally,the textile layers may be left unsealed about the borders or portions ofthe borders to form sealing regions on the borders. For waterproofgarment construction, seam tape can be applied to the sealing regions atthe junctions of garment constructs. Advantages in this constructionmodel of the present invention include the desirability of creating aninterior design which is de-coupled from exterior design. Less seam tapeis required which leads to lighter weight and less bulk in the finalgarment for any given amount of liner pieces.

FIG. 9 shows a side view of an exemplary seam sealed garment or garmentpanel formed by affixing a bondable shell 5 to an inner textile layer 20or liner comprising multiple dissimilar textile pieces. In this example,the bondable shell 5 was sewn and then a seam seal reinforcement 26 ortape was applied over the seam 23. The inner textile layer 20 wasaffixed (using adhesive) as shown so that the inner textile layer 20overlapped the seam tape 26 and was joined contiguously to an adjacentinner textile layer 20 thereby making the seam tape not visible uponviewing the inner textile layer. This construction technique enables thecreation of seam sealed articles wherein the seam sealing means are notvisible when viewed from the inner textile layer 20 side.

FIG. 10 illustrates a useful means to secure accessories including, butnot limited to, pockets and draw cord tunnels for draw cords 100 to theinside of garments. By affixing the accessory (e.g., pocket or draw cordtunnel or the like) to a piece of textile 35, and subsequentlyincorporating this piece of liner textile 35 into the inner textilelayer 20, the accessory is able to be affixed (as shown here viastitches 21) to the inner textile layer 20 of the garment construct asone of a plurality of dissimilar textile pieces forming a part an innertextile layer 20. The inner textile layer 20 is then bonded viadiscontinuous adhesive 10 dots to at least a portion of the bondableshell 5. The bondable shell preferably comprises a functional layer 7which is laminated via a lamination adhesive 150 to the outer textilelayer 15. The present invention may be used to affix accessories toeither side of the functional layer. Furthermore, accessory attachmentvia the present invention avoids the need for seam sealing any stitchingwhich might conventionally be used to sew the accessory to the textilelaminate. Moreover, the reinforcing nature of the inner textile layer 20enables the accessory to have greater durability than if attacheddirectly to the functional layer.

Tests Suter Test for Liquidproof Seams

To determine whether a protective barrier fabric or the seams of agarment made from the protective barrier fabric are waterproof, theSuter test procedure is used, which is based generally on thedescription in ISO 811-1981. This procedure provides a low pressurechallenge to the sample being tested by forcing water against one sideof the test sample and observing the other side for indication thatwater has penetrated through the sample.

The sealed seam test sample is clamped and sealed between rubber gasketsin a fixture that holds the sample so that water can be applied to anarea of the sample 3 inches in diameter (7.62 cm). The water is appliedunder air pressure of 1 psig (0.07 bar) to one side of the sample. Intesting a fabric laminate, the water would be applied to the face orexterior side. In testing a sealed seam, water is applied to the faceside of the sample and the opposite side, or seam backer layer, isobserved for leaks.

The opposite side of the sample is observed visually for any sign ofwater appearing (either by wicking or the appearance of droplets) at theseam edge for 3 minutes. If no water is observed, the sample has passedthe test and the sample is considered liquidproof.

Test for Durably Liquidproof Seams

To determine the durability of a liquidproof seam, the seam sample iswashed and dried generally following the conditions outlined in ISO6330:1984 Procedure No. 3B. Specifically, the sample is loaded in a 4pound (about 2 Kg) load of laundry into a top loading washing machineset to a medium water level (18 gallons, or equivalently 0.0681 m³), hotwater temperature (140° F., or equivalently, 60° C.), warm rinse cycleand heavy duty wash cycle set for 10 minutes, with 90 g of TIDE®powdered laundry detergent. The load is then dried in a rotating dryeron a Hot setting for a 35-45 minute drying time. This wash/dry regimenis repeated five times.

The seam sample is then subjected to the Suter Test for LiquidproofSeams, described above. If no water is observed upon testing, the samplehas passed the test and the sample is considered durably liquidproof.

Test for Moisture Vapor Permeabilty

Moisture vapor transmission rates (MVTRs) were determined using theprocedure set forth in U.S. Pat. No. 4,862,730 using potassium acetateas the salt and open pore ePTFE for the waterproof moisture vaporpermeable membranes. These membranes nominally had a porosity of between75% and 80%, average pore size of 0.2 um, with a thickness ofapproximately 0.04 mm. The environment was maintained at 50% relativehumidity. The water bath was maintained at 23±0.5° C. The samples wereconstrained in a 3″ (about 7.5 cm) diameter plastic hoop and placed onthe bath with woven shell fabric facing up. The purpose of using theplastic hoop was to avoid any buckling of the sample. The samples wereconditioned on the bath with the salt cup on top for about 15 minutesbefore starting the test. The MVTR number is reported in the unit ofg/m²/day.

The following non-limiting examples are provided to further illustratethe present invention.

EXAMPLES Example 1

A seamless garment or garment panel having a liner layer with aplurality of dissimilar textiles with varying moisture vaporpermeability was formed in the following manner:

A two-layer textile laminate was formed comprising a composite barriermembrane as the functional layer laminated to a textile layer. In thisexemplary embodiment, the composite barrier membrane was a composite ofmicroporous polytetrafluoroethylene (PTFE) membrane coated with apolyurethane, prepared according to U.S. Pat. No. 4,194,041 using awater vapor permeable, nonporous polyurethane coating on the ePTFE. Thismembrane was laminated on one side, using a plurality of dots ofmoisture curable polyurethane adhesive, to a polyester woven textilelayer approximately 0.4 min thick and having a weight of approximately100 grams per square meter. The other side of the membrane was coatedwith a discontinuous thermoplastic polyurethane adhesive 10 using aplurality of dots. A first panel having rough dimensions of about 0.6 mby 0.6 m was then cut from this adhesive 10 backed laminate.

A second panel with approximate dimensions of 0.306 m by 0.3 m was cutfrom a polyester fleece textile approximately 1.3 mm thick and having aweight of approximately 160 grams per square meter

A third panel with approximate dimensions of 0.306 m by 0.3 m was cutfrom a polyester tricot knit textile approximately 0.2 mm thick andhaving a weight of approximately 80 grams per square meter.

The second and third panel were then joined to create a fourth panel attheir respective edges by ultrasonically welding in a straight line, 6mm from the panel edge, using a Sonobond Ultrasonic Welding machine(Model No. SM86, Sonobond, Pa.).

The fourth panel consisting of two discrete regions, was then disposedon the thermoplastic adhesive 10 side of the first laminate panel suchthat the edges of the first and fourth panel were coincident. This panelwas placed in a large format heat press (Maxipress Automatic AirOperated Large Format Press, Model No. MAXI-3048AP, Geo Knight and CoInc., Brockton, Mass.) and pressed at 165° C. for 2 minutes, creating asingle seamless garment or garment panel with two discrete dissimilartextiles on the liner side. Each textile region of this sheet was thentested using the Test for Moisture Vapor Permeability, and found to havetwo distinct regions of moisture vapor permeability.

Example 2

A seamless garment or garment panel having a liner layer with aplurality of dissimilar textiles with varying moisture vaporpermeability, a functional layer 7 comprising a composite membranebarrier, and a sealing region was formed in a manner substantially asdescribed in Example 1, with the following exceptions:

The second panel was formed with approximate dimensions of 0.289 m by0.283 m.

The third panel was formed with approximate dimensions of 0.289 m by0.283 m.

The fourth panel consisting of two discrete textile regions was disposedon the thermoplastic adhesive 10 side of the first textile laminatepanel such that the edges of the first and fourth panel were notcoincident. Specifically, the edges of the fourth panel were 17 mm fromthe edges of the first panel, leaving an exposed region of the compositebarrier membrane of the first panel 17 mm wide around the perimeter ofthe bonded panel, referred to herein as the sealing region. Each textileregion of this sheet was then tested using the Test for Moisture VaporPermeability, and found to have two distinct regions of moisture vaporpermeability.

Example 3

A waterproof seam was formed between two garment constructs having linerlayers with a plurality of dissimilar textiles of varying moisture vaporpermeability in the following manner:

Two seamless garment constructs, each having a plurality of dissimilartextiles of varying moisture vapor permeability and a functional layer 7comprising a composite membrane barrier were formed by the methoddescribed in Example 2.

The textile laminate panels were then joined at one of their respectivesealing regions by sewing in a straight line, 6 mm from the panel edge,using a Juki sewing machine (Model No. DLN-415-5, Juki Corporation,Tokyo, Japan), set to 5.1 stitches per cm, followed by trimming of 4 mmoff the seam allowance to ensure that the edge of the resultant 2 mmseam allowance was at least 4 mm from the edge of the textile laminatepanels in either of the non-sealing regions.

A 22 mm width seam tape (GORE SEAM® seam tape obtained from W.L. Goreand Associates, Elkton, Md.), having a hot melt polyurethane adhesive,was then applied to the sealing region by heating the seam tape to atemperature sufficient to melt the polyurethane adhesive 10 and passingthe tape and seam through the nip of a pair of pressure rollers in orderto squeeze the molten adhesive 10 onto the functional layer 7 surface soas to ensure good bonding of the tape to the surface. The tape width wassuch that it covered the entire sealing region and extended about 5 mmbeyond the sealing region on each laminate panel. The resulting seambetween the two laminate panels was tested using the Suter Test forLiquid-proof Seams and determined to be liquid-proof based on passage ofa 0.07 bar/3 minute challenge. The seam was then subjected to the Testfor Durably Liquid-proof laminate, and after the washing regimen, thesample again passed the 0.07 bar/3 minute challenge. Do we need to havea section where we describe the test methods? If so, can we pull fromthe boundary patent?

Example 4

A seamless waterproof garment or garment panel containing a sewn pocket22 on one side which does not compromise the liquid-proofness of thewaterproof garment or garment panel was formed in the following manner:

A two-layer textile laminate was formed comprising a functional layer 7of composite barrier membrane laminated to a textile layer. Thecomposite barrier membrane was a composite of microporouspolytetrafluoroethylene (PTFE) membrane coated with a polyurethane,prepared according to U.S. Pat. No. 4,194,041 using a water vaporpermeable, nonporous polyurethane coating on the ePTFE. This membranewas laminated on one side, using a plurality of dots of moisture curablepolyurethane adhesive, to a polyester woven textile layer approximately0.4 mm thick and having a weight of approximately 100 grams per squaremeter. The other side of the membrane was coated with a discontinuousthermoplastic polyurethane adhesive 10 comprising a plurality of dots. Afirst panel having rough dimensions of about 0.6 in by 0.6 m was thencut from this adhesive 10 backed laminate.

A second panel with approximate dimensions of 0.6 in by 0.6 m was cutfrom a polyester fleece textile approximately 1.3 mm thick and having aweight of approximately 160 grams per square meter.

A third panel with approximate dimensions of 0.1 m by 0.15 m was alsocut from the same polyester fleece textile

The third panel was then attached to the second panel by sewing instraight lines around 3 edges of the perimeter of the third panel, 6 mmfrom the panel edge, using a Juki sewing machine (Model No. DLN-415-5,Juki Corporation, Tokyo, Japan), set to 5.1 stitches per cm, thusforming a pocket on the third panel.

The third panel was then disposed on the thermoplastic adhesive 10 sideof the first textile laminate panel such that the edges of the first andthird panel were coincident. This panel was placed in a large formatheat press (Maxipress Automatic Air Operated Large Format Press, ModelMAXI-3048AP, Geo Knight and Co Inc., Brockton, Mass.) and pressed at165° C. for 2 minutes, creating a seamless waterproof panel containing aon the fleece side. The resulting laminate panel with attachment wastested using the Suter Test for Liquid-proof Seams and determined to beliquidproof based on passage of a 0.07 bar/3 minute challenge.

Example 5

A waterproof down-filled garment or garment panel was formed by thefollowing method:

A two-layer textile laminate was formed comprising a functional layer 7of composite barrier membrane laminated to a textile layer. Thecomposite barrier membrane was a composite of microporouspolytetrafluoroethylene (PTFE) membrane coated with a polyurethane,prepared according to U.S. Pat. No. 4,194,041 using a water vaporpermeable, nonporous polyurethane coating on the ePTFE. This membranewas laminated on one side, using a plurality of dots of moisture curablepolyurethane adhesive, to a Polyester woven textile layer approximately0.4 mm thick and having a weight of approximately 100 grams per squaremeter. The other side of the membrane was coated with a discontinuousthermoplastic polyurethane adhesive 10 comprising a plurality of dots. Afirst panel having rough dimensions of about 0.6 m by 0.6 m was then cutfrom this adhesive 10 backed laminate.

A second panel with approximate dimensions of 0.6 m by 0.6 in was cutfrom a polyester tricot knit textile approximately 0.2 mm thick andhaving a weight of approximately 80 grams per square meter.

A third panel with approximate dimensions of 0.6 m by 0.6 m was cut froma nylon “down proof” woven textile approximately 0.15 mm thick andhaving a weight of approximately 50 grams per square meter

The second and third panels were then attached along their respectiveperimeters to form a fourth panel using a Juki sewing machine (Model No.DLN-415-5, Juki Corporation, Tokyo, Japan), set to 5.1 stitches per cm,leaving an unstitched portion of the perimeter approximately 0.1 in inlength, thus forming a space between the second and third panels.

The space between the second and third panels was then filled with downfeathers, and the remaining 0.1 meters of the perimeter were sewn shutto contain the down feathers between the two panels.

Straight lines were then stitched through this new panel using a Jukisewing machine (Model No. DLN-415-5, Juki Corporation, Tokyo, Japan),set to 5.1 stitches per cm, at an approximate spacing of 0.1 m, tocreate down filled baffles.

The down filled, baffled, fourth panel was then disposed on thethermoplastic adhesive 10 side of the first laminate panel with thetricot knit oriented to the thermoplastic such that the edges of thefirst and fourth panel were coincident. This panel was placed in a largeformat heat press (Maxipress Automatic Air Operated Large Format Press,MAXI-3048AP Geo Knight and Co Inc., Brockton, Mass.) and pressed at 165°C. for 2 minutes, to create a down-filled garment construct.

1.-22. (canceled)
 23. A method of making a garment or garment panelcomprising the steps of: (a) providing a functional layer having a firstside and a second side and an outer perimeter; and (b) affixing an innertextile layer comprised of a plurality of textile pieces to the firstside of the functional layer via a discontinuous layer of adhesive toform a non-homogenous surface wherein at least two textile pieces of theinner textile layer are dissimilar.
 24. The method of claim 23 furthercomprising the step of: affixing an outer textile layer with an outerperimeter to the second side of the functional layer with adiscontinuous adhesive layer.
 25. The method of claim 24 furthercomprising the step of: creating a substantially coincident outerperimeter between the functional layer and the outer textile layer. 26.The method of claim 24 wherein the outer textile layer comprises aplurality of textile pieces to form as non-homogeneous layer.
 27. Themethod of claim 24 wherein the outer textile layer is homogeneous. 28.The method of claim 23 wherein the inner extile layer covers a portionof the functional layer. 29.-31. (canceled)